JPH05228806A - Producltion control system - Google Patents

Abstract

PURPOSE:To realize the most efficient operation, by considering the space and the burden of a worker in a system in which a plurality of automatic production lines comprising plural automatic apparatus are disposed and the same products are produced in parallel. CONSTITUTION:An actual result collecting unit 4 of a production control system 1 collects the production status data of each production line on line, and a predetermined number re-calculating unit 2 replans a production predetermined number dynamically in real time on the basis of the collected data. The production is sequentially ended in the respective lines within a designated period of time by making a difference in sharing between the respective lines. Thus, arbitrary control can be conducted and furthermore replacement for defectives can be performed.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a production control system, and more particularly to a production control system suitable for realizing efficient operation of a production system in which a plurality of production lines simultaneously produce the same product. ..

[0002]

2. Description of the Related Art Due to the recent progress of automation on the production line, for example, a line of a product (for example, a photographic film) of a variety of products and completed through a plurality of processes over a long period of time, Total automation using a computer is possible.

In general, in such an automation system, in order to shorten the construction period, a plurality of production lines simultaneously produce the same product (same lot), and each line communicates information such as LAN. It is connected to an FA computer via a network and is controlled by the FA computer as a whole.

[0004]

The present inventor has made various studies on total automation of an existing photographic film production line, and as a result, the following matters have been clarified. (1) The current FA computer, regarding one processing lot, outputs processing technology information (line processing speed, process information such as lot switching time, etc.) before issuing a production start command to the automatic production equipment that constitutes each line. ) And the planned production quantity of each line, and production is executed based on this information. Further, the FA computer collects the resulting output, but the acquired information is not fed back to the production line. (2) Factors that cause fluctuations in production include failure of automatic equipment (automatic equipment) that constitutes a line and generation of defective products.

As described above, since the acquired information is not fed back to the production, in a situation where such equipment failure or defect occurs, first, at the production end time of the same product in the parallel automatic production lines. There are variations.

[0006] For efficient operation of the line, the next different lots are to be continuously flowed after the production of one lot is completed, so that the worker must supply the feed material for the next lot for each line. Must be prepared with the materials for the current lot to prepare for lot switching. That is, it is necessary to prepare materials for a plurality of products at the same time, which results in a large space for placing the materials. Also,
On the contrary, if the end times happen to be the same, the setup work will concentrate on that time. (3) Further, when a defective product occurs in a certain facility in the automatic production line, it is necessary to re-plan the shortage and separately flow it to the production line, which requires extra production. Further, when a product is produced in anticipation of a defect, and if there is no defective product, the product is overproduced, resulting in waste such as extra storage and material consumption.

The present invention has been made on the basis of the above consideration, and its purpose is to consider the most efficient line in consideration of the space for placing the supply material, the burden on the operator, the compensation of defective products, and the like. It is to realize the operation.

[0008]

The outline of a typical one of the present invention is as follows. (1) The performance collecting unit of the control system collects the performance being produced online from each automatic production facility of each automatic production line constituting the production system. (2) The scheduled number recalculation unit of the control system determines the end time of each automatic production line from the collected results, the planned production number, and process information such as the number of workers, cycle time, and switching time. The planned production quantity of each automatic production line is dynamically recalculated so that the finished products will be sequentially completed within the time and the finished product will match the plan at the end. (3) The production instruction control unit receives the planned production number calculated by the planned number recalculation unit and sends a production command to the automatic equipment. The most upstream equipment (equipment) in each line automatically stops production of the lot when the accumulated production reaches the instructed number.

[0009]

Function: The production end time of the same product on each production line is systematically adjusted so that the production end time falls within an arbitrary time. For example,
When one worker is going to switch lots line by line, if the end time of each line is shifted by the time required to switch to the next lot, there will be no idle time for each line (that is, switchover work will not occur). There is no line that has stopped waiting, so the most efficient operation is achieved. Also,
By systematically controlling the end times of the respective production lines to be the same, it is sufficient to prepare the same material for a plurality of lines, and the space efficiency of the material storage space can be improved.

Further, by feeding back the number of defects generated during the production to the planned production number, the amount of the finished product can be controlled as planned. As a result, there is no shortage of products, there is no reflow to the line again, and no excess, so there is no waste of overproduction.

[0011]

Embodiments of the present invention will now be described with reference to the drawings. (Overall Configuration of Embodiment) FIG. 6 shows the overall configuration of a production control system including a production line. The production line of this embodiment is for producing a photographic film, and the production process is roughly divided into (a) a film 30 drawing process, (b) a mounting process to the cartridge 40, and (c) a carton. (Paper box) 50 packaging process.

Automatic production lines L1, L2, L3 (Ln)
Are equipped with automatic production equipment ac for performing the steps of (a) to (c), and one worker supplies materials line by line to perform work. The number of lines that can be simultaneously switched by one worker is “1”. The materials of each process are stored in the three-dimensional warehouse 110, and the minimum necessary materials are put out to the material storage 100 at the most efficient timing (for example, immediately before the execution of the process) and supplied to the automatic production equipment. It has become. In addition, automatic production line L1,
L2 and L3 (Ln) have the same performance and configuration.
The production control system 1 centrally controls each facility of each automatic production line.

(Structure of Production Control System 1) FIG. 1 is a diagram showing the structure of the production control system 1. This system includes a scheduled number recalculation unit (having a function to recalculate a scheduled number every several tens of seconds) 2, a production instruction control unit 3, and a performance collection unit (acquires line production data every several tens of seconds). 4), technical information (information such as cycle time and lot switching time) database 6, and production planning information (planned quantity Z)
_A, using line (1 to I), using the line number I _A, which comprises the manpower O of _A, etc.) database 7.

(Configuration of Scheduled Number Recalculation Unit 2) FIG. 2 is a diagram showing the configuration of the scheduled number recalculation unit 2. Scheduled number recalculation part 2
In addition to the input / output interface 10, as a functional block (means for realizing a predetermined function, which is constructed as a result of the hardware operating according to the software),
The remaining quantity Q _A of the production amount of the product (probably the product name is A) calculating unit 11, the average remaining production amount R _A calculating unit 12 for each line, and Means for determining the number of groups (D) (group number determining means) when dividing into the same several groups 1
3, group determination means 14 for determining which group each line belongs to, means (correction calculation means) 15 for calculating the corrected quantity H _i for each group, and the planned production quantity Z _i . Means (means for calculating planned production quantity)
And have.

In reality, such a function is, for example, F
Ladder sequence control by A controller (control method that sequentially executes a plurality of series of instructions at the same level)
It is realized by. The functional block configuration of this embodiment has the advantage that the size (granularity) of instructions is relatively uniform and that control by a ladder program is easy.

(Recalculation Operation by Schedule Recalculation Unit 2) FIG.
FIG. 4 is a flowchart showing a recalculation operation procedure by the scheduled recalculation unit 2, and FIG. 4 is a diagram showing a timing example (production state example) regarding production in the four production lines L1 to L4 when the procedure is followed. (This is the case where a 36-shot film lot is manufactured in succession to a 24-shot film lot (ie, product A)).

First, online data is input from the performance collection unit 4 via the input / output interface 10 (step 20). This online data includes the number of good products Ai (i = 1 to n, line number) and the number of defective products Bi of each line.
(I = 1 to n, line number). It is assumed that this data collection is performed at time t1 in FIG.

The remaining amount Q _A calculating means 11 calculates the total amount (that is, the total remaining amount) Q _A of the product A to be produced after the time t1 (step 21). Q _A is calculated by subtracting the cumulative number of non-defective products Ai of each line up to time t1 from the planned amount Z _A , and further adding the cumulative number of defective products Bi.

Next, the R _A calculating means 12 determines the total remaining amount Q.
_A is divided by the number of used lines I _A (4 in the example of FIG. 4) to obtain the average planned production number R _A of each line when the lines are averaged and shared (step 22). what if,
In the case of sharing in this way, the production of the product A on each line ends at the time t4 at the same time.

Next, from time t4, lot switching time WT
By shifting the timings one by one, a procedure for providing a time difference is executed so that the line manufacturing is completed. That is, first, the group number determining means 13 determines how many units the line is divided into and the end time is adjusted (step 23). Assuming that the number of groups is D, D = the number of used lines I _A / the number of workers O _A rounded up. In the case of FIG. 4, D = 4/1 = 4, and the production end time is adjusted for each of the four lines.

Next, a procedure for calculating the planned production quantity is executed for each line. First, the group determination means 14
Determines which group the line i belongs to (step 24). That is, the group number di = i / O _A
Rounded up value of. In the embodiment of FIG. 4, the line L1 belongs to the first group, L2 belongs to the second group, L3 belongs to the third group, and L4 belongs to the fourth group as described above.

Next, the correction number calculation means 15 calculates the correction number H _i of the production amount for providing the time difference for each group (step 25). The H _i = _{[di-D / 2- (I A} + O A -O A · D) · {D / (2I A)} ] · U. However, U is the production number of each line corresponding to the switching time WT. As shown in FIG. 4, in this embodiment, the correction amount is-(3/2) U,-(1/2).
U, + (1/2) U, + (3/2) U.

Next, the planned production quantity calculating means 16 obtains the planned production quantity Z _i (step 26). Z _i = Average planned production number R _{A of} each line + Cumulative number of non-defective products for each line A _i +
The correction number becomes H _i . As a result, the production amount is adjusted for each line so that the production end time is shifted by the lot switching time WT.

Next, the calculated planned production quantity Z _i is sent to the production instruction control unit 3 via the input / output interface 10 (step 27), and the process returns to the first step again. The line control unit 3 notifies the planned production quantity Z _i to the automatic equipment of each line, and gives an instruction to stop when the production of the quantity is completed. As a result, it is possible to realize control that compensates for product reduction due to defective product B _i , secures the planned production amount, and finishes the production of each production line sequentially with a certain time delay. In this way, the dynamic adjustment of the production amount is performed.

After that, the production of the next lot (36 pieces of photographic film) is started in order from the line L1. (Other Example) FIG. 5 is a diagram showing an example in which control is performed in accordance with the procedure of FIG. 3 described above using nine production lines L1 to L9. In this case, the timing of the production end time is adjusted in units of groups 1 to 5. The correction numbers H _i are − (16/9) U, − (7/9)
U, + (2/9) U, + (11/9) U, + (20/9) U
Becomes

Although the production control of lines having the same performance and the same configuration has been described in the above embodiments, the present invention is not limited to this, and control of a plurality of lines having different performances such as cycle time is also possible. The same configuration can be applied. In addition to photographic film, the present invention can be applied to general control when the same product is produced in a plurality of lines. It should be noted that the cycle for collecting the results and recalculating the planned number needs to be appropriately adjusted in relation to the cycle time of the line.

[0027]

As described above, according to the present invention, the information of each production line collected online is fed back to the actual product production to control the production end time of each line and the production amount. As a result, the following effects are obtained. (1) By shifting the end time of each production line little by little, for example, by controlling to sequentially stop at the time interval of switching work, the most efficient operation is achieved without causing idle time in each line. To do. If the production lines are controlled so that the end times are the same, the same material may be prepared for a plurality of lines, and the space efficiency of the material storage space can be improved. (2) By feeding back the number of defects that have occurred during production to the planned number of productions, the amount of finished products can be controlled as planned. As a result, there is no shortage of products, there is no reflow to the line, and there is no excess, so there is no waste of overproduction. (3) With these, it is possible to provide a production amount control system that realizes efficient operation of a production system in which a plurality of production lines simultaneously produce the same product in parallel.

[Brief description of drawings]

FIG. 1 is a diagram showing a configuration of an embodiment of a production control system of the present invention.

FIG. 2 is a diagram showing a specific configuration (function) of a control unit 3 in the embodiment of FIG.

FIG. 3 is a flowchart showing an operation procedure of a control unit 3 in FIG.

FIG. 4 is a diagram for explaining an example of production amount control (an example in which four automatic production lines are individually provided with a time difference to end production) based on the flowchart of FIG. 3;

FIG. 5 is a view for explaining another example of production amount control based on the flowchart of FIG. 3 (an example in which nine automatic production lines are divided into five groups and each of which is provided with a time difference to end the production). It is a figure.

FIG. 6 is a diagram for explaining a more specific situation around the automatic production line in FIG.

[Explanation of symbols]

1 Production amount control system 2 Scheduled number recalculation unit 3 Production instruction control unit 4 Actual result collection unit 6 Technical information database 7 Production planning database 10 Input / output interface 11 Calculation amount of production amount of product A Q _A calculation means 12 For each line average production remaining number R _a calculation unit 13 grouping means 14 each line group determination unit 15 corrects the number of H _i calculating means 16 produce predetermined number Z _i calculating means 30 film 40 cartridge 50 cartons L1~L9 automatic production line

 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Shinichi Kaneko 1 Sakura-cho, Hino-shi, Tokyo Konica Stock Company

Claims (4)

[Claims] 1. A plurality of production lines having a plurality of stages of automatic production equipment are arranged, each automatic production equipment is integrally controlled by a production control means, and each production line operates in parallel to produce the same product. A system for controlling production of a production system that is adapted to produce, wherein the production control means collects performance information in production from each of the automatic production equipment online, and based on the information,
For each of the production lines producing the same product in parallel, the planned production quantity is dynamically re-planned, and the planned production quantity according to the plan is instructed to the automatic production equipment of each production line. A production control system characterized by arbitrarily controlling the production end time of. 2. When the production control means detects that a defective product has occurred in the production line based on the performance information collected online, the production control means adds the defective product number to the remaining product amount to be produced thereafter, and the planned production number. The planned production quantity is divided and allocated to each production line, the future production quantity of each line is determined, and the determined production quantity is instructed to the automatic production equipment of each line. The production control system according to claim 1, wherein the production control system is achieved. 3. The production control means includes a technical information database, a production plan database, a planned production quantity recalculation unit,
Each production line is provided with a performance collection unit and a production instruction control unit for each line, and the planned production quantity recalculation unit serves as a functional block and means for calculating the total remaining production amount (Q _A ) of the product. , The number of groups (D) when calculating the average remaining production amount ( _RA ) for each line and dividing a plurality of production lines into several groups with the same production end time
To determine which group each production line belongs to, a means to calculate a corrected quantity (H _i ) for each group, and an average remaining production quantity of each line ( R _A ) and the correction quantity (H _i ) are added to determine the future planned production quantity (Z _i ) of each production line, whereby the production of each production line is performed for a certain time. 2. The production control system according to claim 1, wherein the control is realized such that the control is sequentially ended while shifting. 4. The production control means includes a technical information database, a production plan database, a planned production quantity recalculation unit,
Each production line is provided with a performance collection unit and a production instruction control unit for each line, and the planned production quantity recalculation unit functions as a functional block by accumulating the total quantity (B) of defective products collected by the performance collection unit. means for calculating _i) total production amount of remaining products in consideration of (Q _a), a calculation unit of the average production remaining number of each line (R _a), a plurality of production lines, the production end time Number of groups (D) when dividing into several same groups
To determine which group each production line belongs to, a means to calculate a corrected quantity (H _i ) for each group, and an average remaining production quantity of each line ( R _A ) and the corrected quantity (H _i ) are added to determine the future production quantity (Z _i ) of each production line, thereby compensating for the reduction in product due to defective products. 3. The production control system according to claim 2, wherein the production amount is secured and the production of each production line is sequentially terminated with a delay of a certain time.